ABB AV3 User manual

INSTRUCTION MANUAL
Characterizable Pneumatic Positioners
Type AV3 and AV4
PN25058

Copyright 2002 ABB Inc. [August 2002]
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Registrations and trademarks used in this document include:
® Dow Corning is a registered trademark of Dow Corning Corporation
WARNING notices as used in this manual apply to hazards or unsafe practices which could result in personal
injury or death.
CAUTION notices apply to hazards or unsafe practices which could result in property damage.
NOTES highlight procedures and contain information which assist the operator in understanding the informa-
tion contained in this manual.
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owned by ABB Inc. or its suppliers.
WARNING
POSSIBLE PROCESS UPSETS. Maintenance must be performed only by qualified personnel and only after
securing equipment controlled by this product. Adjusting or removing this product while it is in the system may
upset the process being controlled. Some process upsets may cause injury or damage.
NOTICE
The information contained in this document is subject to change without notice.
ABB Inc., its affiliates, employees, and agents, and the authors of and contributors to this publication specifi-
cally disclaim all liabilities and warranties, express and implied (including warranties of merchantability and fit-
ness for a particular purpose), for the accuracy, currency, completeness, and/or reliability of the information
contained herein and/or for the fitness for any particular use and/or for the performance of any material and/or
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of materials and/or equipment is at the sole risk of the user of this publication.
This document contains proprietary information of ABB Inc., and is issued in strict confidence. Its use, or repro-
duction for use, for the reverse engineering, development or manufacture of hardware or software described
herein is prohibited. No part of this document may be photocopied or reproduced without the prior written con-
sent of ABB Inc..

Table of Contents
Page
i
SECTION 1 - INTRODUCTION ....................................................................................................1-1
INTRODUCTION.............................................................................................................................1-1
INTENDED USER ...........................................................................................................................1-1
TYPE AV3/4 POSITIONER DESCRIPTION ...................................................................................1-1
TYPE AV3/4 POSITIONER APPLICATION ....................................................................................1-2
TYPE AV3/4 POSITIONER FEATURES .........................................................................................1-2
INSTRUCTION CONTENT .............................................................................................................1-3
HOW TO USE THIS INSTRUCTION BOOK ...................................................................................1-4
REFERENCE DOCUMENTS ..........................................................................................................1-5
TYPE AV3/4 POSITIONER NOMENCLATURE .............................................................................1-5
SPECIFICATIONS ..........................................................................................................................1-6
ACCESSORIES .................................................................................................................1-10
SECTION 2 - DESCRIPTION AND OPERATION........................................................................2-1
INTRODUCTION.............................................................................................................................2-1
FUNCTIONAL OPERATION ...........................................................................................................2-2
SECTION 3 - INSTALLATION .....................................................................................................3-1
INTRODUCTION.............................................................................................................................3-1
UNPACKING AND INSPECTION ...................................................................................................3-1
ENCLOSURE CLASSIFICATION ...................................................................................................3-2
MOUNTING CONSIDERATIONS ...................................................................................................3-2
MOUNTING TYPE AV3 AND AV4 POSITIONERS.........................................................................3-2
CONNECTING TUBING TO TYPE AV POSITIONER ....................................................................3-7
Filtering Supply Air ...................................................................................................................3-8
Recommended Supply Air Quality ...........................................................................................3-8
Tubing Connections .................................................................................................................3-8
WIRING TYPE AV POSITIONER....................................................................................................3-9
SECTION 4 - CALIBRATION.......................................................................................................4-1
INTRODUCTION.............................................................................................................................4-1
GENERAL CALIBRATION ..............................................................................................................4-1
AV3 Calibration ........................................................................................................................4-1
ZERO ADJUSTMENT (AV3).............................................................................................4-2
SPAN ADJUSTMENT (AV3).............................................................................................4-3
AV4 Calibration ........................................................................................................................4-3
ZERO ADJUSTMENT (AV4).............................................................................................4-4
SPAN ADJUSTMENT (AV4).............................................................................................4-4
SERVO MOTOR SPEED ADJUSTMENT (AV4) ..............................................................4-5
CALIBRATION FOR PARTICULAR APPLICATION (AV3 ONLY) ..................................................4-7
Zero Adjustment.......................................................................................................................4-7
Span Adjustment......................................................................................................................4-7
GAIN AND SPEED ADJUSTMENTS ..............................................................................................4-8
Gain Adjustment.......................................................................................................................4-8
Speed Adjustment....................................................................................................................4-9
ORIFICE SPEED CONTROL............................................................................................4-9
SPEED CONTROL BY PILOT VALVE STROKE ADJUSTMENT.....................................4-9
TROUBLESHOOTING CALIBRATION ADJUSTMENTS..............................................................4-11
Servo Assembly Adjustments (Type AV3 Positioner) ............................................................4-11
Servo Adjustments (Type AV4 Positioner).............................................................................4-14

ii
Table of Contents (continued)
Page
SECTION 5 - OPERATING PROCEDURES................................................................................5-1
INTRODUCTION .............................................................................................................................5-1
EQUALIZING AND AIR SUPPLY SHUTOFF VALVE......................................................................5-1
Transfer from Automatic to Manual Operation .........................................................................5-1
Transfer from Manual to Automatic Operation .........................................................................5-1
SECTION 6 - TROUBLESHOOTING...........................................................................................6-1
INTRODUCTION .............................................................................................................................6-1
SECTION 7 - MAINTENANCE.....................................................................................................7-1
INTRODUCTION .............................................................................................................................7-1
ROUTINE SERVICE........................................................................................................................7-1
SECTION 8 - REPAIR/REPLACEMENT PROCEDURES ...........................................................8-1
INTRODUCTION .............................................................................................................................8-1
MANIFOLD FILTERS ......................................................................................................................8-1
MANIFOLD ......................................................................................................................................8-2
GAIN HINGE SPRING.....................................................................................................................8-3
PILOT VALVE BODY ......................................................................................................................8-4
SERVO ASSEMBLY AND ELECTRONICS CIRCUIT BOARD .......................................................8-5
CAM.................................................................................................................................................8-7
DIAPHRAGM ASSEMBLY...............................................................................................................8-8
Removing .................................................................................................................................8-8
Replacing .................................................................................................................................8-8
PILOT VALVE STROKE ADJUSTMENT.........................................................................................8-9
SECTION 9 - SUPPORT SERVICES...........................................................................................9-1
INTRODUCTION .............................................................................................................................9-1
RECOMMENDED SPARE PARTS..................................................................................................9-1
ADDITIONAL SPARE PARTS KITS ................................................................................................9-2
APPENDIX A - POSITION TRANSMITTERS ............................................................................. A-1
INTRODUCTION ............................................................................................................................ A-1
DESCRIPTION AND OPERATION ................................................................................................ A-1
Potentiometric Position Transmitter......................................................................................... A-1
Four to 20 mA Position Transmitter......................................................................................... A-1
CALIBRATION................................................................................................................................ A-2
Calibrating the Potentiometric Position Transmitter ................................................................ A-2
POTENTIOMETRIC APPLICATION EXAMPLE .............................................................. A-3
CALIBRATE THE POTENTIOMETRIC APPLICATION EXAMPLE ................................. A-4
Calibrating the Four to 20 mA Position Transmitter................................................................. A-6
APPENDIX B - QUICK START................................................................................................... B-1
INTRODUCTION ............................................................................................................................ B-1
PRODUCT IDENTIFICATION (NOMENCLATURE)....................................................................... B-1
MOUNTING THE POSITIONER..................................................................................................... B-2
EXTERNAL TUBING CONNECTIONS........................................................................................... B-4
EXTERNAL WIRING CONNECTIONS........................................................................................... B-4
CALIBRATION................................................................................................................................ B-5

iii
Table of Contents (continued)
Page
APPENDIX C - CAM CHARACTERIZATION ............................................................................. C-1
INTRODUCTION............................................................................................................................ C-1
CAM CHARACTERIZATION.......................................................................................................... C-1
CAM SELECTION .......................................................................................................................... C-3
CAM SHAPING METHOD..............................................................................................................C-5
List of Figures
No. Title Page
1-1. Capacity Data of Type AV3/4 Positioners (Exhaust to Atmosphere)........................................1-8
1-2. Air Consumption Data of Type AV3/4 Positioners....................................................................1-8
2-1. Type AV3/4 Positioner Operation Diagram...............................................................................2-1
2-2. Block Diagram of a Typical Control System Utilizing a Positioner............................................2-1
3-1. External and Mounting Dimensions for the Type AV Positioner...............................................3-3
3-2. Typical Positioner Mounting Using Linkage .............................................................................3-4
3-3. Typical Positioner Mounting Using Direct Coupling .................................................................3-4
3-4. Drive Arm Connections ............................................................................................................3-5
3-5. Positioning Cam .......................................................................................................................3-6
3-6. Cam Roller Alignment ..............................................................................................................3-7
3-7. Type AV Positioner Port Locations ...........................................................................................3-9
3-8. Tubing Examples of Single-Acting Actuators .........................................................................3-10
3-9. Tubing Example of a Double-Acting Actuator ........................................................................ 3-11
3-10. Type AV Positioner Wiring Connections................................................................................. 3-11
4-1. Type AV Calibration Adjustment Locations ..............................................................................4-2
4-2. Cam Roller Alignment ..............................................................................................................4-3
4-3. Type AV4 Positioner Motor Speed Adjustments.......................................................................4-6
4-4. Zero Adjustment Graph............................................................................................................4-7
4-5. Span Adjustment Graph ...........................................................................................................4-8
4-6. Pilot Valve Measurement for Maximum Speed.......................................................................4-10
4-7. Speed Adjustment Screw Locations....................................................................................... 4-11
4-8. Type AV3 Positioner EMI/Electronics Housing....................................................................... 4-13
4-9. Servo Adjustments (AV4) .......................................................................................................4-15
8-1. Type AV Positioner with Manifold.............................................................................................8-1
8-2. Manifold without Filter Cover....................................................................................................8-2
8-3. Manifold (Rear View) Showing O-Rings...................................................................................8-3
8-4. Servo and EMI/Electronics Assembly ......................................................................................8-6
8-5. Stroke Adjustment Screw Locations.......................................................................................8-10
8-6. Pilot Valve Measurement for Maximum Speed.......................................................................8-10
9-1. Type AV3 Positioner (Interior, Wiring, and Tubing Details).......................................................9-5
9-2. Type AV3 Positioner (Exploded View)......................................................................................9-6
9-3. Type AV3 Positioner (Front, Side and Inside of Cover)............................................................9-7
9-4. Type AV4 Positioner (Interior, Wiring, and Tubing Details).......................................................9-9
9-5. Type AV4 Positioner (Front, Side and Inside of Cover)..........................................................9-10
9-6. Type AV4 Positioner (Exploded View).................................................................................... 9-11
A-1. Terminal Block Connections TB1-1 through TB1-5 ................................................................. A-2
A-2. Schematic for Potentiometric Position Transmitter Example ................................................. A-4
A-3. Potentiometric Position Transmitter Assembly (Exploded View)............................................. A-5
A-4. Location of Calibration Features for 4 to 20 mA Position Transmitter.................................... A-6

List of Figures (continued)
No. Title Page
iviv
A-5. 4 to 20 mA Position Transmitter Assembly (Exploded View)................................................... A-8
B-1. Typical Positioner Mounting Using Linkage............................................................................. B-2
B-2. Typical Positioner Mounting Using Driect Coupling................................................................. B-3
B-3. Drive Arm Connections............................................................................................................ B-3
B-4. Cam Roller Alignmment........................................................................................................... B-4
B-5. Type AV Positioner Port Locations .......................................................................................... B-4
B-6. Tubing Examples of Single-Acting Actuators .......................................................................... B-5
B-7. Tubing Example of a Double-Acting Actuator.......................................................................... B-6
B-8. Type AV Wiring Connections................................................................................................... B-7
B-9. Type AV Calibration Adjustment Locations.............................................................................. B-8
B-10. Type AV4 Positioner Motor Speed Adjustment...................................................................... B-10
C-1. Cam A, Square Root Relationship........................................................................................... C-1
C-2. Cam B, Linear Relationship..................................................................................................... C-2
C-3. Cam C, Square Relationship ................................................................................................... C-2
C-4. Regulated Device Characteristics ...........................................................................................C-3
C-5. Desired Control ....................................................................................................................... C-4
C-6. Cam Characteristics ................................................................................................................ C-5
C-7. Transferring Data from the Graph to the Cam......................................................................... C-6
List of Tables
No. Title Page
1-1. Reference Documents..............................................................................................................1-5
1-2. Type AV3/4 Nomenclature .......................................................................................................1-5
1-3. Type AV 3/4 Positioner Specifications......................................................................................1-6
1-4. Optional Potentiometric Position Transmitter Specifications....................................................1-9
1-5. 4 to 20 mA Position Transmitter Specifications .......................................................................1-9
1-6. Agency Approvals ....................................................................................................................1-9
1-7. Positioner Accessories ...........................................................................................................1-10
1-8. Rotary Actuators Retrofitting Mounting Kits............................................................................1-10
1-9. Optional Speed Control Orifices.............................................................................................1-10
1-10. Pressure Gages .....................................................................................................................1-11
1-11. Supply Air Regulators with Gages..........................................................................................1-11
1-12. Supply Air Filters ....................................................................................................................1-11
3-1. Positioner Cam Characteristics ................................................................................................3-6
4-1. Servo Motor Speed Adjustment (Coarse and Fine)..................................................................4-5
4-2. Gain Hinge Spring Characteristics ...........................................................................................4-9
6-1. Positioner Errors.......................................................................................................................6-1
9-1. Pilot Valve Assembly Kit ..........................................................................................................9-1
9-2. AV Diaphragm Assembly Kit ...................................................................................................9-1
9-3. Filter Replacements Kit ...........................................................................................................9-2
9-4. Shutoff Valve Kit ......................................................................................................................9-2
9-5. Cam..........................................................................................................................................9-2
9-6. Manifold Assembly Kit ............................................................................................................9-2
9-7. Gain Hinge Springs Kit ............................................................................................................9-2
9-8. Servo Assemblies.....................................................................................................................9-3
9-9. Electronics Board Assemblies ..................................................................................................9-3

v
No. Title Page
List of Tables (continued)
9-10. Potentiometric Position Transmitter .........................................................................................9-3
9-11. Cover Assembly Kit .................................................................................................................9-3
9-12. Cam Follower Arm Kit .............................................................................................................9-3
9-13. Type AV3 Positioner Parts List for Figures 9-1, 9-2 and 9-3....................................................9-4
9-14. Type AV3 Reference for Cam and Manifold ............................................................................9-6
9-15. Type AV3 Reference for Output and Drive Shaft .....................................................................9-7
9-16. Type AV4 Positioner Parts List for Figures 9-4, 9-5, and 9-6...................................................9-8
9-17. Type AV4 Reference Table....................................................................................................9-10
9-18. Positioner Mounting Kit .........................................................................................................9-12
9-19. Positioner Mounting Kit .........................................................................................................9-12
9-20. Positioner Mounting Kit .........................................................................................................9-13
9-21. Rotary Actuators Retrofitting Mounting Kits ...........................................................................9-13
A-1. Transmitter Assembly Parts List .............................................................................................A-8
B-1. Type AV3/4 Nomenclature ...................................................................................................... B-1
B-2. Calibration Procedures............................................................................................................ B-8
B-3. Motor Speed Adjustment (AV4 Only) ...................................................................................... B-9
B-4. Servo Motor Speed Adjustment (Coarse and Fine) .............................................................. B-10
C-1. Relationship of Input to Output for I/P Converter (AV3) .......................................................... C-3

Read First I
Read First
WARNING
INSTRUCTION MANUALS
Do not install, maintain or operate this equipment without reading,
understanding and following the proper factory-supplied instructions and
manuals, otherwise injury or damage may result.
RETURN OF EQUIPMENT
All equipment being returned to the factory for repair must be free of any
hazardous materials (acids, alkalis, solvents, etc.). A Material Safety Data
Sheet (MSDS) for all process liquids must accompany returned equipment.
Contact the factory for authorization prior to returning equipment.
Read these instructions before starting installation;
save these instructions for future reference.
Contacting the Factory . . .
Should assistance be required with any of the company’s products, contact the following:
Telephone:
24-Hour Call Center
1-800-HELP-365
E-Mail:
[email protected]om

INTRODUCTION
1 - 1
SECTION 1 - INTRODUCTION
INTRODUCTION
This section covers the following topics:
•Type AV3/4 description.
•Type AV3/4 application.
•Features of positioners.
•Instruction content.
•How to use this instruction book.
•Type AV3/4 nomenclature.
•Type AV3/4 specification.
•Position transmitter specification.
•Agency approvals.
•Accessories.
•Mounting kits.
NOTE: Appendix B provides a quick start guide for the Type AV
positioner. It is intended for control engineers having experience in
the use and application of pneumatic positioners. The quick start
guide highlights the major points of installation and calibration.
Detailed installation and calibration information is contained in
Section 3 and 4.
INTENDED USER
The information in this publication is a guide for technical person-
nel responsible for installation, calibration, operation, maintenance
and repair of the Type AV3/4 positioner.
TYPE AV3/4 POSITIONER DESCRIPTION
The Type AV3 and Type AV4 positioners are electro-pneumatic
control devices that satisfy a wide range of applications. They pro-
vide fast, sensitive and accurate positioning of pneumatic single or
double acting actuators.
The Type AV3 positioner accepts a four to 20 milliamp current that
is applied to an I/P (current to pneumatic) converter (located
inside the housing) to generate an internal signal pressure. The
Type AV4 positioner responds to a solid state (DDC) or contact
closure input to generate a similar internal signal pressure.
If a loss of signal occurs, both Type AV3 and AV4 positioners
retain their position just prior to the signal loss (referred to as fail
in place).

INTRODUCTION
TYPE AV3/4 POSITIONER APPLICATION
1 - 2
A mechanical connection from the actuator (i.e., cylinder, valve,
etc.) to the position feedback cam in the positioner establishes
actual position. Three characterized segments on the cam provide
application flexibility by establishing various relationships between
the input signal and the actuator position. The characterized
curves on the cam provide:
•Square root relationship.
•Linear relationship.
•Square characteristic.
Using zero, span and gain adjustments and the cam, the actuator
can respond with characteristics specific to an application.
An optional manifold assembly provides an integral shutoff and
equalizing valve that can be used to isolate the positioner from an
actuator, allowing manual override without removing the positioner
from the process. The manifold also provides gage ports and dis-
posable filter cartridges that insure fast servicing and minimum
downtime.
The Type AV3 positioner can be equipped with either an optional
potentiometric or a four to 20 milliamp position transmitter. The
Type AV4 positioner comes standard with a four to 20 milliamp
position transmitter.
TYPE AV3/4 POSITIONER APPLICATION
The ABB Type AV3 and Type AV4 Characterizable Pneumatic
Positioners control the position of a pneumatic actuator in a linear
or nonlinear relation to a current or pulse input signal.
TYPE AV3/4 POSITIONER FEATURES
•Troublefree Operation. Proven pilot valve, that is quickly
removable, provides less downtime, lower maintenance costs,
increased reliability and extended performance.
•Compact Rugged Design. Die cast aluminum housing,
beam, spring arm, follower arm and 303 stainless steel pilot
valve provide long life and maximum environmental protec-
tion. The compact housing increases mounting flexibility.
•Characterizable Output. Large positioning cam can be
shaped to provide desired relationship between the input sig-
nal and the actuator position.
•Accurate Calibration. Independent zero and span adjust-
ments eliminate interaction and provide fast and accurate cali-
bration.

INTRODUCTION
INSTRUCTION CONTENT
1 - 3
•Simplified Reverse Operation. Action can be changed in the
field by changing cams and reversing 01 and 02 connections.
The reverse-acting cam is conveniently located on the inside
of the front cover.
•Highly Visible Position Status Indicator. A fluorescent
orange position indicator is visible through a polycarbonate
window, providing fast indication of actuator position.
•Vent Design Allows Natural Gas Operation. Vent pipe
arrangement permits operation using natural gas.
•Split Range Service. Split range capability allows sequencing
of multiple actuators using a single control signal.
•Adjustable Gain. Two levels of gain are possible by simply
changing the hinge springs supplied with the positioner.
•Adaptable Usage. The positioner can control both single and
double-acting, linear and rotary type actuators.
•High Capacity. More than 0.65 cubic meters per minute (23
standard cubic feet per minute) can be supplied or exhausted
from the positioner at 483 kilopascals (70 pounds per square
inch) supply pressure. See Figure 1-1 in SPECIFICATIONS.
•Continuously Adjustable Span and Zero for Each Stroke
Level. Capable of 100 percent stroke for 50 percent signal
span or 50 percent stroke for 100 percent signal span.
•Low Air Consumption. Enhanced pilot valve design and
manufacturing technique allows the Type AV positioner maxi-
mum performance with minimum air consumption. See Figure
1-2 in the SPECIFICATIONS section.
•Adjustable Speed Control without Additional Hardware.
Speed of actuator can be reduced to desired speed using the
pilot valve stroke adjustment screws.
INSTRUCTION CONTENT
This document includes the following sections:
Introduction Provides a description of this instruction book; its sections and
uses, along with a brief description of the Type AV3 and Type AV4
positioners. This section also provides product nomenclature
(Table 1-2), specifications (Tables 1-3, 1-4, 1-5), instructions on
how to use this document, agency approvals (Table 1-6) and posi-
tioner accessories (Table 1-7). Table 1-8 lists retrofit mounting kits,
Table 1-9 lists available speed control orifices, and Table 1-10 lists

INTRODUCTION
HOW TO USE THIS INSTRUCTION BOOK
1 - 4
the available pressure gages. Table 1-11 lists pressure regulators
and Table 1-12 lists supply air filters available from ABB.
Description and
Operation
Describes the functional operation of the positioners.
Installation Provides information about installing a Type AV positioner.
Calibration Provides calibration and adjustment procedures.
Operating Procedures Presents information and procedures for various applications suit-
able for Type AV positioners.
Troubleshooting Provides a table containing errors, causes, and corrective action
for Type AV positioners.
Maintenance Includes maintenance information and procedures on Type AV
positioners.
Repair/Replacement Provides step-by-step instructions for removing and replacing
components of Type AV positioners.
Support Services Provides recommended and replacement parts lists. Illustrations
of both positioners provide part numbers for all major components.
Appendix A Provides calibration information about the four to 20 milliamp posi-
tion transmitter and potentiometric position transmitter.
Appendix B Contains quick start information for control engineers who are
knowledgeable about positioners and the overall process in which
the positioner is to be used.
Appendix C Details cam shaping information.
HOW TO USE THIS INSTRUCTION BOOK
For safety and operating reasons, read and completely under-
stand this product instruction book before installing or completing
any tasks or procedures associated with operation.
The section arrangement of this instruction book is sequential.
After initial start-up and calibration, store this manual in a safe
place for future reference.

INTRODUCTION
REFERENCE DOCUMENTS
1 - 5
REFERENCE DOCUMENTS
TYPE AV3/4 POSITIONER NOMENCLATURE
Table 1-1. Reference Documents
Number Document Title
ANSI/NFPA 70 National Electrical Code
CEC Canadian Electrical Code
C-P88-21 Characterizable Positioners, Type AV1, AV2, AV3, AV4 (Specification)
CSA C22.1 Process Control Equipment
PN25039 Characterizable Pneumatic Positioner, Type AV1 and AV2 (Instruction book)
ISA S7.3 Quality Standards for Instrument Air (Instrument Society of America)
ISA S75.13-1989 Method of Evaluating the Performance of Positioners with Analog Input Signals
and Pneumatic Output (Instrument Society of America)
P-P88-001 Installing a Type AV Positioner in a Hazardous Location (Product Application
Guide)
Table 1-2. Type AV3/4 Nomenclature
Position345678
Type AV □ □ □ □ □ □ Characterizable Positioners
Type
3Characterizable 4 to 20 mA Input Positioner
(fail in place upon loss of signal)
4Characterizable Pulse Input Positioner
(fail in place upon loss of signal)
Input Signal
34 to 20 mA (Type AV3)
4Contact closure/open collector DDC (Type AV4)
Stroke/Rotary Motion (cam selection)
112.7 - 50.8 mm (0.5 - 2.0 in.) or 45°rotary motion
225.4 - 101.6 mm (1.0 - 4.0 in.) or 90°rotary motion
Manifold (includes filters)
0None
1Manifold with equalizing valve
2Manifold without equalizing valve
Position Transmitter1
0None (Type AV3 and Type AV4)
1Potentiometric resistive output (Type AV3 only)
24 to 20 mA Output (Type AV3 only)
Drive Shaft
0Standard with drive arm
1½-inch square end
NOTE:
1. When ordering Type AV44, position 7 must be 0. The 4 to 20 mA output position transmitter is not an option, it is a standard feature of
Type AV44 positioner. The position transmitter options are only valid for Type AV33 positioners.

INTRODUCTION
SPECIFICATIONS
1 - 6
SPECIFICATIONS
Table 1-3 provides performance specifications of the Type AV3
and Type AV4 positioners. Tables 1-4 and 1-5 provide perfor-
mance specifications for the position transmitters.
Table 1-3. Type AV 3/4 Positioner Specifications
Property Characteristic/Value
Input Range
Type AV3 4 to 20 mA DC (30 VDC maximum)
Type AV4 Computer DDC (direct digital control), solid state or contact closure
input.
Units have 50% range suppression and/or zero elevation capability.
Minimum pulse width test data taken at 20°C (68°F) and factory pre-
set fine speed adjustment. Operation at other fine speed adjustment
settings will require different minimum pulse widths. Operation at
colder temperatures may require longer minimum pulse widths.
Voltage Supply (Type AV4
only)
Minimum 16 VDC
Nominal 24 VDC
Maximum 34 VDC
NOTE: Maximum 50 mA current draw.
Input Impedance1<1.66 kΩat 4 mA
<0.57 kΩat 12 mA
<0.35 kΩat 20 mA
Standard Stroke Range
(cam selection)
Type AV1 positioner 12.7 to 50.8 mm (0.5 to 2.0 in.) linear, rotary input 45°
Type AV2 positioner 25.4 to 101.6 mm (1.0 to 4.0 in.) linear, rotary input 90°
NOTE: It is recommended that the 90° cam be used wherever possible (Type AV2 po-
sitioner).
Gain Two adjustment levels by changing gain hinge spring.
Accuracy1,2 0.70% of span typical; <0.90% of span maximum
Resolution <0.30% of span maximum
Hysteresis1,2 0.35% of span typical; <0.60% of span maximum
Repeatability1,2 0.40% of span typical; <0.60% of span maximum
Minimum Pulse Width
Coarse Speed
Adjustment Position Msecs
440
320
215
1 12.5

INTRODUCTION
SPECIFICATIONS
1 - 7
Dead Band2<0.30% of span maximum
Linearity1,2 0.60% of span typical; <0.80% of span maximum
Supply Pressure 172 to 1,034 kPa (25 to 150 psig)
Supply Pressure2Effect
Single-acting 0.05%/6.9 kPa for ±69 kPa change
0.05%/1.0 psi for ±10 psi change
Double-acting 0.05%/6.9 kPa for ±35 kPa change
0.05%/1.0 psi for ±5 psi change
Capacity (max. capacity,
exhausting to atmosphere)
See Figure 1-1.
Air Consumption See Figure 1-2.
Positioner Weight
Type AV3
Type AV4
2.27 kg (5 lbs)
2.35 kg (5 lbs 3 oz)
Temperature Limits3
Operating
Storage
-20°to 60°C (-4°to 140°F)4
-20°to 80°C (-4°to 176°F)
Temperature Effect
Type AV3
Type AV4
<0.18% per °C (<0.09% per °F)
<0.03% per °C (<0.015% per °F)
Vibration Effect2Less than 2.0% error for:
5 to 15 Hz at peak to peak constant displacement of 4 mm (0.16 in.)
15 to 120 Hz at accelerations to 2 Gs
RFI Effect
Type AV3
Type AV4
±1.5% maximum at 10 V per meter field strength, 20 to 540 MHz
±1.5% maximum at 10 V per meter field strength, 20 to 450 MHz
Pneumatic Connections ¼-NPT on supply, signal, and output connections
-NPT on pressure gages
Materials of Construction
Enclosure
Pilot Valve
Aluminum, and <0.5% magnesium
303 Stainless Steel
Enclosure Classification NEMA 3R classification when vent hole is protected from rain using
rain elbow (½-14 NPT street elbow, see Figure 3-1). Corrosion resis-
tant to NEMA 4X test requirements (NEMA 250).
NOTES:
1. Not applicable to the Type AV4.
2. Tested according to ISA-S75.13-1989.
3. Operation below specification (not recommended) will increase stroke time.
4. For operation below 4.4×C (40×F, )dew point of the supply air must be -7.7×C (18×F) lower than the lowest expected operating temper-
ature.
SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE
Table 1-3. Type AV 3/4 Positioner Specifications (continued)
Property Characteristic/Value
18
⁄

INTRODUCTION
SPECIFICATIONS
1 - 8
Figure 1-1. Capacity Data of Type AV3/4 Positioners
(Exhaust to Atmosphere)
Figure 1-2. Air Consumption Data of Type AV3/4 Positioners
FLOW
(SCFM)
SUPPLY PRESSURE
(PSIG)
40
30
20
T00769A
10
0020304010 50 60 70 80
SUPPLY CAPACITY
EXHAUST CAPACITY
FLOW
(SCFM)
SUPPLY PRESSURE
(PSI)
20 40 50 60 70 80 90 10030 110 120 130 140 150
T00336A
0.90
0.80
0.70
0.60
0.50
0.40
0.30
0.20
0.10
0

INTRODUCTION
SPECIFICATIONS
1 - 9
Table 1-4. Optional Potentiometric Position Transmitter
Specifications (Type AV331 Only)
Property Characteristic/Value
Total Resistance 2,000 Ω ±20%
Power Rating 1 W up to 70°C (158°F)
0 W at or above 125°C (257°F)
Wiper Rate of
Change
9.9 Ω nominal per degree of cam rotation
Temperature Effect 0.05% (500 ppm) per °C
0.03% (278 ppm) per °F maximum
Maximum Voltage 35 VDC or 30 VAC across the potentiometer ends
SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE
Table 1-5. 4 to 20 mA Position Transmitter Specifications
(Type AV332 and AV440)
Property Characteristic/Value
Supply Voltage 16 to 34 VDC
Output Signal 4 to 20 mA
Output Loading 500 Ωat 24 VDC
1000 Ωat 34 VDC
Accuracy 0.6% of span maximum
Hysteresis 0.5% of span maximum
Repeatability 0.4% of span maximum
Ambient Tempera-
ture Effect
0.063% per °C
0.035% per °F
EMI/RFI Effect 1.5% maximum at 10 volts per meter field
strength, 20 to 450 MHz
SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE
Table 1-6. Agency Approvals
Nomenclature Approval/Certification
AV3/41, 2 FM and CSA approval and certifications in the
following categories:
Nonincendive for Class I, Division 2,
Groups A, B, C, D.
Intrinsically safe for Class I, Division 1,
Groups A, B, C, D, when used with an
approved intrinsic safety barrier.
NOTES:
1. Approvals and certifications pending. The position transmitters of Type AV3/41/2 posi-
tioners are CSA certified and FM approved in the categories listed.
2. Hazardous location approvals for use in flammable atmospheres are for ambient conditions of
-25°to 40°C (-13°to 104°F), 86 to 106 kPa (12.5 to 15.7 psi) with a maximum oxygen concentra-
tion of 21%.

INTRODUCTION
ACCESSORIES
1 - 10
ACCESSORIES
Table 1-7. Positioner Accessories1
Accessories Description
Mounting Kits Dependent on valve stem size.
For ABB rotary actuator retrofit kits, refer to Table 1-8.
Speed Control
Orifices
Regulate time constant of positioner and final control device. Orifices are installed
directly into positioner output ports (refer to Table 1-9). Speed adjustment can also
be controlled by using the internal stroke adjustment screws (refer to GAIN AND
SPEED ADJUSTMENTS in Section 4).
Pressure Gages For reading signal supply and output pressures, refer to Table 1-10.
Blank Cam Used to characterize the positioner if the standard cams (square, linear, square
root) will not produce the desired relationship. Blank cam must be profiled (part
number 5400277_1).
Regulator Refer to Table 1-11.
Air Filters ABB recommends installing an air filter in the supply air line to prevent particles
from entering the positioner, which can lead to malfunction. Refer to Table 1-12 for
filter part numbers.
NOTE:
1. For recommended spare parts and additional spare parts, refer to Section 9.
Table 1-8. Rotary Actuators Retrofitting Mounting Kits
Retrofit
Mounting Kit
Drive
Nomenclature Kit Number
AP positioner
to AV positioner
UP10, UP20
UP3, UP4
UP5, UP6
5400309_1
258493_1
258494_1
AC0404
AC0608
258527_1
258528_1
AC0816
AC1016
258529_1
258530_2
Pilot valve positioners to
AV positioners
AC0404
AC0608
258527_1
258528_1
AC0816
AC1016
258529_1
258530_1
Table 1-9. Optional Speed Control Orifices1
Orifice Size Orifice Part
Number
mm in.
1.02 0.04 5327327_1
Blank Drill to suit 5327327_2
NOTE:
1. Speed control can also be obtained by internal positioner adjustment, re-
fer to GAIN AND SPEED ADJUSTMENTS in Section 4.

INTRODUCTION
ACCESSORIES
1 - 11
Table 1-10. Pressure Gages
Range Legend Part Number
kPa psi
0 - 200 0 - 30 Instrument 5326605_4
0 - 1000 0 - 160 Supply15326605_5
0 - 1000 0 - 160 Output 5326605_6
NOTE:
1. The optional manifold provides gage ports, one for instrument (internal
input signal) and two output gages. A supply gage can be installed in the
supply line (piping by customer).
Table 1-11. Supply Air Regulators with Gages
Part Number Max. Outlet
Pressure (psi)
Max. Inlet
Pressure (psi)
Inlet/Outlet
Connections
1951029_1 60 250 ¼-NPT
1951029_3 30 250 ¼-NPT
1951029_5 100 250 ¼-NPT
1951439_1 100 250 -NPT
Table 1-12. Supply Air Filters1
Part
Number
Max. Inlet
Pressure
(psi)
Maximum
Temperature Inlet/Outlet
Connection Size
°C°F
5328563_1 150 54.4 130 ½-NPT
5328563_2 250 121 250 ½-NPT
NOTE:
1. In-line coalescing filter for removal of solid and liquid contaminants in compressed air. Filter
comes with universal mounting bracket and grade DX filter which is 93% efficient at 0.1 micron.
Part number 5328563_2 has an anodized aluminum bowl guard.
38
⁄

INTRODUCTION
I-P88-24A1 2 - 1
SECTION 2 - DESCRIPTION AND OPERATION
INTRODUCTION
This section describes and explains the functional and physical
operation of Type AV3 and AV4 positioners. Figure 2-1 diagrams
operating principles of the positioners. Figure 2-2 shows the
placement of a Type AV positioner in a typical system.
Figure 2-1. Type AV3/4 Positioner Operation Diagram
PILOT VALVE
CAM
SIGNAL
DIAPHRAGM
DIAPHRAGM
FORCE
RANGE
SPRING
FORCE
RANGE SPRING
4-20 mA
OR
PULSE SIGNAL
T02000A
GAIN
HINGE
SPRING
BALANCE BEAM
SIGNAL PRESSURE
3-15 PSIG
EMI/ELECTRONICS
AND
SERVO
ASSEMBLY
SUPPLY PRESSURE
TO ACTUATOR
O2
S
O1
TO ACTUATOR
Figure 2-2. Block Diagram of a Typical Control System Utilizing a Positioner
+
–
+
–
SET
POINT
+
–
CONTROLLER
POSITION
TRANSMITTER
(OPTIONAL)
POSITIONER ACTUATOR PROCESS OUTPUT
LOAD
T00770A
LINKAGE
PROCESS FEEDBACK